SVE Mustang Aluminum Radiator Install (05-09)

Posted 12/21/2016 by Tyler Rodriquez

Adding a lightwieght aluminum radiator to your 2005-2009 Mustang is a great way to drop weight from your S197 and improve your cooling system efficiency. Installing an aluminum radiator in a 2005-2009 Mustang is a pretty easy step by step process. Follow along as customer Jeremy Howell walks you through his install!

FOLLOW: 05 09 mustang , mustang , sve

How To Install How To Install Mustang Aluminum Radiator (05-09)

Tools Needed:

  • Pliers
  • Flat head screwdriver
  • 8mm and 10mm sockets
  • Ratchet wrench with 4 inch extension
  • 8mm ratcheting wrench
  • Drain pan
  • Installation Instructions

    1. Make sure the car has cooled off. Vent the overflow tank cap and then support the car via a lift or jack stands.


    2. Remove the plastic push pins securing the radiator cover and then set this aside.



    3. Loosen and remove the 8mm retaining bolt securing the power steering reservoir to the fan shroud.



    4. Rotate this out of your way and make sure that it is upright so fluid doesn’t run out.



    5. Slide the small hose clamp back away from the reservoir.



    6. Loosen and remove the two 8mm bolts securing the reservoir to the fan shroud and move the reservoir out of your way.



    7. Go ahead and remove the two upper radiator hold down brackets. (These are secured to the core support with 10mm bolts.)



    8. From underneath the car, remove the 5.5mm screws securing the lower splash shield to the front bumper and lower radiator support.



    9. Place a piece of hose onto the nipple and then remove the drain plug.



    10. Locate the two 10mm nuts on each side of the radiator.



    11. Up top, remove the upper hose from the radiator and position it out of your way.




    12. Locate the electrical connection for the fan and disconnect it.




    13. Just above the electrical connection, remove the other 8mm fan shroud retaining bolt.Remove the fan shroud from the car.




    14. locate and remove the two 8mm bolts securing the upper brackets for the A/C condenser.




    15. Remove the lower radiator hose.




    16. Remove the radiator from the bottom.




    17. With the factory radiator out of the car, remove the two lower studs and install them on the new radiator.




    18. Install the new SVE radiator.




    19. Reinstall everything in reverse fashion.




    20. Use a funnel and fill the cooling system with fresh coolant.




    21. Double check everything and you’re all finished.



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    About the Video

    How To Install 2005-2010 Mustang GT SVE Radiator

    Check out our YouTube channel for even more tech tips, installation videos, how-tos, and more. The best place to go for anything Mustang related!

    Published on 2017-11-14
    Mustang SVE Aluminum Radiator.
    Increase cooling efficiency, and capacity, in your 2005-2010 Mustang GT with SVE's all aluminum radiator! Your factory S197 radiator is anemic, and getting to the age where a leak could spring at any moment. Replace your stock radiator with SVE's 100% aluminum replacement radiator. Aluminum provides better heat dissipation to increase efficiency, and keep your engine temps low on even the hottest days. SVE's radiator is a direct bolt-on, and a quick fix for clogged, leaking, or damaged factory radiators. Whether you are daily driving, road racing, or drag racing; this SVE radiator is perfect for any 2005-2010 Mustang!

    SVE Quality.
    SVE's aluminum radiator features a 3 row, cross flow design that improves coolant flow over your factory radiator. The 3 row core, and all aluminum tanks, increase coolant capacity to ensure your S197 is running cool at all times. Beautiful, TIG weld beads flow across all seams of the radiator to ensure leak free performance that lasts. High efficiency air fins allow maximum airflow in any driving condition. A plastic drain plug with rubber o-ring is included for easy servicing. Factory size inlets, and outlets, are utilized to make SVE's radiator a quick and easy installation!

    Radiator Dimensions.
    Overall Dimensions: 29-9/16"W x 21-5/8"H x 5-3/4"D
    Core Size: 23-7/8"W x 19-3/8"H x 2"D
    Inlet Diameter: 1.5"
    Outlet Diameter: 1.5"

    Fitment Note:
    - Fits both manual and automatic transmissions.

    Application: 2005-2010 Mustang GT

    Item # SVE-8005E
    Transcript
    To begin, make sure the car has cooled off. DO NOT open the cooling system while under pressure.

    Go ahead and vent the overflow tank cap and then support the car via a lift or jack stands.

    Remove the plastic push pins securing the radiator cover and then set this aside.

    For additional clearance and work room, I went ahead and removed the cold air intake that was on this car.

    Loosen and remove the 8mm retaining bolt securing the power steering reservoir to the fan shroud.

    Rotate this out of your way and make sure that it is upright so fluid doesn’t run out.

    Slide the small hose clamp back away from the reservoir.

    Place a rag underneath hose and then remove it from the reservoir.
    Loosen and remove the two 8mm bolts securing the reservoir to the fan shroud.

    Carefully position the reservoir out of your way.

    Go ahead and remove the two upper radiator hold down brackets.

    These are secured to the core support with 10mm bolts.

    From underneath the car, remove the 5.5mm screws securing the lower splash shield to the front bumper and lower radiator support.

    Set the lower splash shield aside.

    Position a drain or bucket underneath the drain plug on the radiator.

    Place a piece of hose onto the nipple and then remove the drain plug.

    While the coolant is draining from the system, locate the two 10mm nuts on each side of the radiator.

    Remove these and set them aside.

    Up top, remove the upper hose from the radiator and position it out of your way.

    Locate the electrical connection for the fan and disconnect it.
    Just above the electrical connection, remove the other 8mm fan shroud retaining bolt.

    Remove the fan shroud from the car.

    Now, locate and remove the two 8mm bolts securing the upper brackets for the A/C condenser.

    There is one bolt per side.

    Position the drain pan or bucket underneath the lower radiator hose and remove it from the radiator.

    You may have to position the hose out of its support bracket to completely remove it from the radiator.

    Be sure and remove the bucket or drain pan, and the hose from the nipple on the radiator.

    Because of the lower studs, I found it easiest to drop the radiator out from the bottom.

    With the factory radiator out of the car, remove the two lower studs.

    This done by using an inverted Torx bit or in my case a pair of channel locks.

    Someone had been here before and had broken the tip of the stud completely off.

    Transfer these to the front of the new radiator and into the lower thread inserts.
    Then, carefully tighten them down.

    Unlike the removal process, I positioned the new SVE radiator into place from the top.

    Make sure the lower locating dowels are positioned into the rubber isolators on the lower radiator mount.

    Now, reusing the factory hardware, install the upper condenser bracket into the upper thread insert on the radiator.

    Do this for both sides.

    Slide the condenser into the upper brackets and then position it over the studs.

    Reposition the power steering cooler and retighten the two 10mm nuts.

    Make sure the drain plug is installed and fully tightened.

    Reinstall the lower splash shield.

    Reposition the lower radiator hose and clamp.

    Also, make sure the hose is fully seated in the support bracket.

    Reinstall the two upper radiator hold down brackets.

    Reposition the fan and tighten down the passenger side retaining bolt.

    Reconnect the electrical connection.

    Reinstall the upper radiator hose and clamp.

    Reposition the overflow tank and retighten the hardware.

    Do the same for the power steering reservoir.

    On the factory radiator, remove the small hose from the nipper and transfer it to the new radiator.

    Be sure and reinstall it onto the nipple on the overflow tank.

    Reposition the air box, and then reinstall and reconnect its components.

    Remove the overflow tank cap.

    Use a funnel and fill the cooling system with fresh coolant.

    Fill the coolant reservoir with fresh coolant until it reaches the “cold fill range”.

    Start the car and let the water pump circulate the coolant.

    Add any additional coolant, turn the car off and tighten the cap.

    Reinstall the radiator cover.

    If you’re adding more coolant, be sure the car is off and cool to the touch.

    At operating temperature, the system is under pressure.

    Double check everything and you’re all finished.